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Flex-Ray Is Designed for Plastic Injection Molding Machines

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Flex-Ray Is Designed for Plastic Injection Molding Machines International Journal of Science and Research (IJSR) ISSN (Online): 2319‐7064 Flex-Ray is Designed for Plastic Injection Molding Machines B. Gomatheeshwari1, M. S. Vishnu Priya2 1Student, Sri Muthukumaran Institute of Technology, Chennai – 600069, India 2Assistant Professor, Sri Muthukumaran Institute of Technology, Chennai – 600069, India Abstract: This innovative application of the Flex-ray technology with the ARM controller is implemented to monitor and control the process of the injection molding machine with the help of host computer. Embedded technology and Flex-ray field bus technology are utilized together for the efficient functioning of injection molding machine. The closed-loop control system, composed of the ARM controller and sensors, realizes the prompt adjustment of the processing parameters, such as temperature, flow, injection pressure and the control of multi-stage injection pressure in the molding process to produce best product in best quality. Flex-ray technology with Artificial Intelligence used in this process to monitor and control the parameters at the high transmission rate. Keywords: Flex-Ray Transceiver, injection moulding machine; distributed control system; artificial intelligence. 1. Introduction of the HSE communication role used in Foundation Fieldbus. At present, the control mode of injection molding machines is mainly stand-alone control, which cannot 2. System Architecture Design provide the network control function for injection molding machines. The maintenance and the management for the The ARM-based distributed intelligent control system machines are also limited to on-site management level. mainly consists of the host computer, FLEX-RAY This kind of operation and management mode is not only fieldbus, ARM controller as the slave computer and other unable to meet the requirements of automation and scale accessories, as shown in Fig.1. The control center of the production, but also it is harm to the operator’s health system, host computer, together with FLEX-RAY fieldbus, because they are long time working in the environments connects all ARM controllers scattered in different that is full of machine noise and plastic smell. In order to working locations, realizing the distributed intelligent solve the problems mentioned above, the best way is to control for the injection molding machines. The main develop a kind of flexible, effective and practical control functions of the host computer include the initialization of system of injection molding machine and establish the the network, the communication management between the automation production line. In regard to this, a new ARM controllers, file transfer, the status monitoring of the distributed intelligent control system based on ARM and machines, product information statistics, the remote FLEX-RAY field bus was presented in this paper. This maintenance of the systems and the software upgrades. control system can realize the distributed intelligent The ARM controller, as the middle bridge, can provide the control and the on-site monitoring of the injection molding remote control for the host computer and can carry on the machine. Besides, the hardware composition and software local control for the machine, such as the setting and design scheme of this control system are also discussed in modifying the processing parameters, detecting, displaying this paper. FlexRay is an option for upgrading existing and controlling the status parameters such as the injection network systems using CAN in the automotive industry as pressure, the flow, the temperature and so on. well as other industrial control applications. It could also be used for new applications in industrial automation, where safety and reliability in a work environment is of utmost importance, due to its deterministic approach to communication of the messages. This is helped by the use of a two channel topology where each channel is able to work independently, but the two channels can also be used to communicate the same information and as such has built in redundancy. The FlexRay protocol has been designed to carry information at a rate of 10Mbits/s over each of its two channels while CAN has a data rate of 1Mbit/s [3][8]. This means that an equivalent data rate of 20Mbits/s can be achieved which is twenty times that of a CAN based system. The high bit rate of FlexRay systems makes it suitable as the basis of a network backbone even where CAN is already in use. A Fieldbus network has a data rate of around 31.5Kbits/s. When the data rate is compared to that of FlexRay there emerges a view that FlexRay, if used with an existing CAN system, could take on a similar role Figure 1: Block diagram Volume 3 Issue 4, April 2014 Paper ID: 020131211 www.ijsr.net 284 International Journal of Science and Research (IJSR) ISSN (Online): 2319‐7064 3. Network Topology 4.1 TDMA The Flex-Ray protocol defines a two channel network, In a TDMA system the communication cycle is broken channel A and channel B. A node can be attached to one or down into smaller time segments referred to as slots. The both of these channels. If a node is attached to a single duration of the slots in the static segment are the same. channel it does not matter if it is channel A or channel B. The slots are assigned to a given communication node so The Flex-Ray protocol allows for various bus topologies. that in every communication cycle only that node can These can be a point to point connection, passive star, transmit at that time. It should be noted that Flex-Ray does linear passive bus, active star network, cascaded active provide a cycle multiplexing system so that information stars, hybrid topologies and dual channel topologies. The can be sent out every odd cycle for example. This allows FlexRay protocol will support hybrid topologies as long as another message to be sent in that slot during the even the limits of each topology which makes up the hybrid communications cycles and again this message would also topology( i.e. the star and bus topologies) are not exceeded be set to that slot in that multiple of the communication shows the possible connections in a dual channel cycles. Also a node may get more than one slot per configuration. segment depending on the setup of the system and the need to send different messages. This approach to message arbitration leads to a very deterministic networking scheme making it very suitable for monitoring and safety systems applications. 4.2 Static Segment The static segment is broken down into smaller sections called static slots. Every static slot is of the same duration. During transmission each slot is assigned to a specific message and only that message can transmit during that slot time. Figure 2: Flex-ray topology 4.3 Dynamic Segment 4. Flex-Ray Hardware The Dynamic segment is an optional section of the Each node has a communication controller, a host, a power communication cycle. It is broken down into smaller supply unit and two bus drivers, one for each channel. Fig sections known as minislots. If a node wishes to 3 [8] shows the logical connections of each element. The communicate it must wait until its minislot comes around. host handles the applications of the system while the If no transmission occurs after a given period the minislot FlexRay protocol is handled by the communications counter is incremented and the node with the next controller. The bus driver is used to read and write data to message/frame id may begin transmission of data. The the physical medium over which the data is transmitted. In data to be sent will only be sent if there is enough time left sleep mode it also has the ability to start the wakeup in the dynamic segment. In this way the dynamic segment procedure if it detects a wakeup symbol. The is priority driven with the message with the lowest ID communications controller will mainly handle the framing having the highest priority, just like CAN. of data and the checking of received data to ensure it was uncorrupted before passing it to the host. The host and 4.4 Symbol Window communications controller share information such as control information and payload data from the host, while A symbol is used to signal a need to wake up a cluster the communication controller relays status information and amongst other things. This depends on the symbol sent and data received. The host interface to the bus driver allows it the status of the controller at the time. Within the symbol to change the operation of the bus driver as well as read window a single symbol may be sent. If there is more than status and error flags. one symbol to be sent then a higher level protocol must determine which symbol gets priority as the Flex-Ray protocol provides no arbitration for the symbol window. 4.5 Network Idle Time The network idle time is used to calculate clock adjustments and correct the node’s view of the global time. It also performs communication specific tasks and uses up the remaining time of the communication cycle. Figure 3: Flex-ray protocol 5. Frame Format The frame of a Flex-Ray message is broken down into 3 sections: the header, payload and trailer section as seen is Fig 6. When compared to the CAN frame format, both Volume 3 Issue 4, April 2014 Paper ID: 020131211 www.ijsr.net 285 International Journal of Science and Research (IJSR) ISSN (Online): 2319‐7064 standard format and extended format, it can be seen that 6. Result analysis the frame format of Flex-Ray is much larger. This is partly due to the extra error checking. The header section contains status information such as status bits indicating if the fame is a null frame, i.e.
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